77 sheet metal work

[byrd_hntr]

So Ive finally broke down and decided to start dealing with some rust issues. I know it going to be a long road. One of these days Im going to be driving down the road the the seat that is under by A$$ will fall out of the truck on the ground and the cruiser will just keep going. I started by pulling the seat our last night and assessing the damage. I think I have my work cut out for me. Ive been practicing on scrap metal and will continue to do so. Here a few pics of the devastation. It will be a long slow process I think. Ill be welding with a Hobart 210 MVP which is an excellent machine that for sure.

Stay tuned to see some more carnage and hopefully a happy ending.

 

[byrd_hntr]

And the cutting begin

Started cutting. Kinda of a weird feeling. No going back now.

Should I remove the tranny hump or can I work around it?

 

[brian]

Started cutting.

that's the hard part. once the first cut is made, the hard work is over. all you need to do is dig in and go now.

 

[pb4ugo]

This is how it starts! You probably need to pull the hump & the gas tank. Nothing like welding w/a gas tank sitting next to ya.

 

[sggoat]

The t-hump doesn't look to be in that bad of shape. May want to remove it, though, so you don't arc it accidentally. - also you could then rebolt the thing once the floor is complete.--would give you more room to work--

 

[byrd_hntr]

Yeah, no gas tank while welding. Thats for sure. The fun continues tomorrow.

 

[White Stripe]

I would pull the tranny hump, you will likely find rust where it mounts to the floor that you may want to fix.

 

[byrd_hntr]

I would pull the tranny hump, you will likely find rust where it mounts to the floor that you may want to fix.

Your probably right. The hump looks ok, and steel is solid under it but Im going to pull it and clean it up anyway. I sprayed all the bolts down with PB blaster last night. Crossing my fingers for minimal broken bolts.

 

[snaggletto]

Stop cutting and get a plan, otherwise you will be waist deep in a frame off restoration and won't be driving it for years. Figure out what steel is good and what is bad. Order a patch panel and cut only what you need to fit it. If you aren't going after an oem restoration, I would consider fitting some home brew patches, concentrate on structural integrity and save the money. You will have to rework and modify most aftermarket patches anyway, and they won't match the oem ribbs. Just my opinion after installing a new reproduction panel under my drivers seat last year. Good luck. Remember, fj40's are no fun when you can't drive them.

 

[byrd_hntr]

Stop cutting and get a plan, otherwise you will be waist deep in a frame off restoration and won't be driving it for years. Figure out what steel is good and what is bad. Order a patch panel and cut only what you need to fit it. If you aren't going after an oem restoration, I would consider fitting some home brew patches, concentrate on structural integrity and save the money. You will have to rework and modify most aftermarket patches anyway, and they won't match the oem ribbs. Just my opinion after installing a new reproduction panel under my drivers seat last year. Good luck. Remember, fj40's are no fun when you can't drive them.

Who said I didn't have a plan? If you look closely at the pic you will see a patch panel leaning against the door frame? My plan it to patch the floor so I don't fall through. I don't want to do a years long resto. My plan is to do little project over a weekend span or so so I can drive it this summer.

 

[bikersmurf]

Looks like you're on the right track... And trust me that tub ain't bad...

I daily drove my 40 while I built a new 1/2 tub on the truck over the course of many weekends over the summer, so I know it doesn't need to turn into a frame off... Replacing the frame was a year or so later.

 

[overpaid slacker]

let me know if you need a hand with welding and fab. I am just up the road outside of Lyons. Up to my eyeballs with metal fabrication on my 76.

 

[byrd_hntr]

I got a little farther tonight. I hoping to be burning metal tomorrow but of course every step I take I find more rust.

Ive got a but more to cut out under the pedal as you can see. I appear the I can save the channel. Some wire wheel and paint should bring it around.

 

[fj401978]

Looks like you're doing great! It's always the same with these ol' girls...once you start removing things, you find more rust or more problems. It's a labor of love...lol. Sometime in the next year or so, I'm gonna have to tackle my floorboards. Thanks for posting your project and progress! Good luck, and keep giving us some good pics to look at

 

[brian]

Remember, fj40's are no fun when you can't drive them.

false

 

[dad4x4]

I will echo what has already been said, Looks like progress to me. that is what it is all about, being able to take a couple weekends to cut and weld to make your cruiser better. I too have a 77 and in the middle of replacing rusty panels as well. Keep posting pics of the progress.

 

[winnie]

a never ending battle ... good news is you have something to weld to, and the frame rails and cross members look good ...

 

[SSCR]

Can you tell me if there was a bracket of some sort bolted to the floor in the circle? I know there is an oval hole with a grommet for the fuel lines, and a round hole with a grommet for the wring harness but I'm not sure what is bolted to the floor there. Thanks

 

[byrd_hntr]

Can you tell me if there was a bracket of some sort bolted to the floor in the circle? I know there is an oval hole with a grommet for the fuel lines, and a round hole with a grommet for the wring harness but I'm not sure what is bolted to the floor there. Thanks

Yes, there is a bracket there. I think it's for the heater hoses but as you can see my hoses are not in it. I can get some better pics if that will help.

 

[SSCR]

Yea, that would be great!